Method for packaging rolls



Oct. 11, 1966 L. J. BUDD 3,277,627

METHOD FOR PACKAGING ROLLS Original Filed Feb. 26, 1962 4 Sheets-Sheet 1 m INVENTOR.

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mmmon FOR PACKAGING ROLLS Original Filed Feb. 26, 1962 4 Sheets-Sheet 2 A21 INVENTOR.

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METHOD FOR PACKAGING ROLLS Original Filed Feb. 26, 1962 4 Sheets-Sheet 3 INVENTOR. 16/460 M 5 0 TTORNEYS Oct. 11, 1966 L. J. BUDD 3,277,627

METHOD FOR PACKAGING ROLLS Original Filed Feb. 26, 1962 4 Sheets-Sheet 4 INVENTOR. AAPPr 500p A TTORNE YS United States Patent 3,277,627 METHOD FOR PACKAGING ROLLS Larry J. Budd, Elmhurst, Ill., assignor to Pallet Devices, Inc., Des Plaines, Ill., a corporation of Illinois Original application Feb. 26, 1962, Ser. No. 175,646, now

Patent No. 3,214,015, dated Oct. 26, 1965. Divided and this application July 26, 1963, Ser. No. 297,773

14 Claims. (Cl. 53-29) The present application is a division of my copending application Serial No. 175,646, filed on February 26, 1962, now Patent No. 3,214,015 issued October 26, 1965, entitled Method and Apparatus for Packaging Rolls.

The present invention relates generally to methods of making packaging structures. More particularly, the present invention relates to a method for packaging rolls.

In the packaging industry, considerable difiiculty has been experienced by packagers in the packaging of long relatively heavy rolls of material such as foil, cellophane, polyethylene sheets, and the like, and which weight about 150 pounds each depending on the material wound on the roll. It has been found that it has not been desirable to ship rolls of this type while lying fiat on a surface because the rolls tend to assume an egg or oval shape which interferred with the removal and use of the material wound on the rolls and which may also result in damaging the material.

An important object of the present invention is to provide a roll shipping carton and method of manufacturing the same which may be readily adapted for suspending a roll having material wound thereon with the material extending to the opposite ends of the rolls or with the material being spaced from the opposite ends of the roll.

Still another important object of this invention is to provide new and improved roll support pads and methods of manufacturing the same.

Yet another important object of this invention is to provide a new method of packaging rolls of material.

According to still other features of the present invention, there is provided a method of packaging rolls of material which method includes the steps of forming a base with a vertical wall structure, notching the wall structure to provide wall openings in opposing walls, aligning tubular rolls between the opposing walls with the wall openings, forming roll holders each by punching a series of annularly disposed fingers from a sheet of material and turning the fingers laterally from the sheet and engaging rings against inner and outer faces of the fingers forming a tubular end on the roll holders, and telescoping the thus formed tubular ends through the wall openings into the interior of the tubular rolls suspending the tubular rolls in spaced relation from said opposing walls and engaging a flange end of each of said holders against the outside face of the associated opposing wall.

Still another important feature of the present invention relates to the manufacturing of a new and improved roll shipping carton.

Other objects and features of the present invention will more fully become apparent in view of the following detailed description taken in conjunction with the accompanying drawings illustrating several embodiments and in which:

FIGURE 1 is a persepective view of a roll shipping carton;

FIGURE 2 is an enlarged exploded view of the ship ping carton shown in FIGURE 1 with certain components shown in section, which section is taken substantially on the line IIII looking in the direction indicated by the arrows, as seen in FIGURE 1;

FIGURE 3 is an enlarged vertical section taken sub- 3,277,627 Patented Oct. 11, 1966 stantially on the line III--III looking in the direction indicated by the arrows, as shown in FIGURE 1;

FIGURE 4 is a layout view of a blank for forming the wall structure of the carton shown in FIGURE 1;

FIGURE 5 is a layout view of the blank for forming one of the cushioning pads employed on the carton shown in FIGURE 3;

FIGURE 6 is an end elevation of the blank shown in FIGURE 5 only illustrating the manner in which the foldable pad sections are folded for forming the cushioning p FIGURE 7 is a top plan view of a cushioning pad formed from the blank illustrated in FIGURES 5 and 6;

FIGURE 8 is an enlarged cross-sectional view taken substantially on the line VIII-VIII looking in the direction indicated by the arrows, as shown in FIGURE 7;

FIGURE 9 is a top plan view of a blank for forming another cushioning pad also employed on the curtain shown in FIGURE 3;

FIGURE 10 is a top plan view of a modified cushioning pad formed from the blank shown in FIGURE 9;

FIGURE 11 is an enlarged cross-sectional view taken substantially on the line XIXI looking in the direction indicated by the arrows, as shown in FIGURE 10;

FIGURE 12 is a top plan view of a blank for forming a roll holder or cushioning pad;

FIGURE 13 is a cross-sectional view taken substantially on the line XIIIXIII looking in the direction indicated by the arrows, as shown in FIGURE 12;

FIGURE 14 is an enlarged vertical section similar to FIGURE 3 only illustrating the carton having a modified type of cushioning pad mounted on the exterior of the carton;

FIGURE 15 is a top plan view of the cushioning pad shown in FIGURE 14;

FIGURE 16 is a perspective view of still another modified type of carton;

FIGURE 17 is a layout of a blank used in the formation of one of the bottom sections of the carton shown in FIGURE 16; and

FIGURE 18 is an enlarged fragmentary cross-sectional view taken substantially on the line XVIIIXVIII looking in the direction indicated by the arrows, as shown in FIGURE 16.

As shown on the drawings:

The reference numeral 10 indicates generally a roll shipping carton. The carton 10 includes a base 11 having legs 12 secured to its underside which legs are preferably of the type shown in the Larry J. Budd et al. Patent 2,507,588. The carton 10 further includes a wall structure 13 and a cover 14 is mounted on top of the wall structure providing an end closure for the carton 10. Extending between the legs 12 of the carton and around the walls of the carton are a series of metal straps 15 for holding the components of the carton in assembly together.

Mounted within the carton 10 are a series of rolls 16 having material 16a wound thereon. The material may comprise foil, polyethylene, cellophane, and the like. The rolls may be between 42 inches to 60 inches long and may weigh about pounds apiece depending upon the material carried on the roll.

In accordance with important features of this invention, it will be noted that a series of roll holders 17 are extended through wall openings in the wall structure 13 which wall openings are illustrated as defined by circular wall edges 18. Mounted on the wall structure 13 about the openings are a series of roll supporting pads or cushioning pads 19 and 20. In order to mount the tubular roll 16 on the wall structure 13, the rolls 16 are inserted into the carton and the ends of the rolls are aligned with 3 opposed wall openings 18 and the roll holders 17 are guided through the wall openings 18 to suspend the rolls on the Wall structure 13. The rolls are engaged with the roll supporting pads 19 and 20 to provide a rigidified reinforced roll supporting carton.

In the first form of the invention, the base 11 and the cover 14 are of an identical construction except that the legs 12 are formed on the base 11 preferably as shown in FIGURES 6-9 in the Budd et al. Patent 2,507,588. A blank for forming a base similar to the one here employed is shown in FIGURE 17 which will be hereafter described in further detail.

The wall structure 13 is formed from a blank 21 and is scored at score lines 22-27 to form side walls 28-31, attachment flap 32, upper closure flaps 33-36 and lower closure flaps 37-40. The blank at 21 is punched to provide the openings 18 and the flap 33 is stapled at S to the flap 30 in order to secure the side walls in a rectangular form. In general, the wall structure 13 as well as the base 11 and the cover 14 may be each formed from a single blank of relatively rigid form-sustaining sheet material and preferably of an inexpensive expendable material such as paperboard, fiberboard or the like. These structures are formed by making bends at score lines which may be scored by marking the blank or preferably by actual indentations of the blank, especially when the blank is of paperboard or a like material, but it will be appreciated that marking or indentation is not necessarily required and that the terms scoring and score line are therefore used in a figurative sense to indicate the position of the bends.

The pad 20 is formed from a blank 41 which is punched providing rows of circular edges 42 defining the blank openings. The blank is scored and partially slit along score lines 4343 forming a main pad section 44 and foldable pad sections 4545. The sections 4545 are each joined with section 44 by a layer of paper comprising a joint 46. When the sections 45 are folded, the circular edges 42 are converted into semi-circular roll engaging edges 47. The sections 4545 are glued at 48 to section 44 in order to completethe formation of the pad 20 (FIGURE 8).

The pad 19 is formed from a blank 50 (FIGURE 9) and is scored and partially slit along score line 51 dividing the blank into pad sections 5252. The blank 50 is further provided with circular edges or openings 53. The pad 50 is folded with paper layer 54 providing a folded joint between the pad sections 5252 and the sections are then glued or otherwise suitably secured as indicated at 55. The circular edges of the blank 50 are converted into semicircular roll engaging edges 5656 after the blank 50 is folded in half.

The roll holders 17are each formed from a blank 60 (FIGURE 12) which is punched to cut out a center opening defined by the edge 61 and slit along line 62 forming slit sections 63. Fingers or projections 64 are formed by the slitting operation upon turning the slit section 63 away from the collar flange 65. Inner and outer rings or tubes 66 and 67 are glued at 68 joining the rings or tubes with the fingers 64 to form a roll supporting tubular portion 69 on the roll holder 17.

The components of the carton may be assembled in a number of ways. One manner of assembling the components is by initially folding the flaps 37-40 underneath the wall structure 13 and telescoping the wall structure in assembly with the dished base 11. The rolls are then disposed one by one within the confines of the wall structure and aligned with the wall openings 18 whereupon the roll holders 17 are telescoped through the wall openings and into the interior of the tubular rolls 16 to fix the roll in assembly with the wall structure. In order a to lock the lower roll holders 17 with the wall structure, the wall structure 13 may be elevated slightly to permit the collar end of the roll holder to be engaged flush against the carton wall structure 13. The wall structure is then released so that the vertical side wall 11a of the base is engaged with the flanged end 65 of the roll holder to lock it in assembly with the wall structure 13 and with the associated roll 16. The other rolls 16 are assembled with the wall structure and then the cover 14 is engaged on top of the wall structure and its vertical side wall 14a is lapped over the flanged end 65 of the roll holder in the same manner as previously described to lock the roll holder 17 with the wall structure 13 and with the associated roll 16. Thereafter, the bands 15 may be attached to the carton to secure the components in unitary assembly.

During the attachment of the rolls with the side walls by means of the holders 17, the cushioning pads 19 and 20 are placed in position within the carton. To this end, a pair of cushioning pads 19 is initially placed and supported on the flaps 37-40 in such a way that the notches 56 extend vertically upwardly. After the lower rolls are engaged in the notches 56, the second set of cushioning pads are then locked in the carton with the notches 47 engaging the lower rolls and are supported thereon. The upper set of rolls is then disposed within the carton and supported on the cushioning pad edges 47. The uppermost or third set of pads is then mounted on the carton in such a way that its edges 56 are engaged within the rolls. The flaps 33-36 of the wall structure 13 are then folded over the cover 14 in assembly with the wall struc ture 13 in the manner previously described.

In FIGURES 14 and 15 is shown a modified carton 10". The carton 10" is especially adapted for carrying rolls 16" having material 16a" wound thereon which material extends to the opposite ends of the roll 16". Primed reference numerals have been used to identify the various components of the carton 10 which correspond to and are substantially identical to the components of the previously described carton 10.

Since the rolls 16" cannot readily be supported on cushioning pads from within the carton without damaging the material 16a" on the rolls, cushioning pads 78 are secured to opposing walls of the wall structure 13". The cushioning pads 78 may comprise a double thickness of paperboard and may be stapled or glued or otherwise suitably secured to the wall structure 13" of the carton 10". Each of the cushioning pads 78 is provided with a series of circular edges defining openings 79. Tubular ends of the roll holders 17" are extending through the pad openings into the interior of the rolls 16" whereby the rolls 16" are supported by the wall structure edges 18" as well as by the cushioning paidedges 79.

The components of the carton 10 may be assembled in the same manner as previously described. Initially the components, including the base 111", the wall structure 13" and the cover 14" are assembled. The cushioning pads 78 are attached to opposite side walls of the wall structure 13" in such a way that the openings 79 are aligned with the wall openings 18". The rolls are then secured to the side walls of the wall structure by means of the holder 17" in the same manner as already described.

In FIGURES 16-18, inclusive, is illustrated still another modified roll supporting carton 10'. Primed reference numerals have been employed for the purposes of identifying parts which are similar or identical to corresponding parts already described on the carton 10.

The carton 10' is substantially identical to the carton 10 only the wall structure 13' is not formed as a separate element or unit as in the first form, but rather is formed integral in one piece with the base 11' itself. Also, a series of covers 14' are employed, one (for each base 11. Throughout the specification and claims, it Will be appre ciated that the term wall structure has been used in a generic sense in that it may be formed either integral with the base, as shown in FIGURE 16, or it may comprise a separate structure as indicated at 13 in FIGURE 1, and as formed from the blank 21 illustrated in FIGURE 4.

Each of the bases 11 shown in FIGURE 16 may be formed from a blank 80 as shown in FIGURE 17. The

lowermost base diflers from the upper ones in that it is not provided with leg openings such as is illustrated in FIGURE 3 and from which the holder fingers 64 are turned.

The blank 80 is provided with criss-crossed score lines 90-93 providing a main base section 81, side walls or sections 82-85 as well as corner flaps 8689. After the blank has been scored as described, and after the corner flaps have been partially slit, the side walls :are turned away from the base section, and the corner flaps are folded as shown in FIGURE 17 and stapled at S to an adjoining side wall to complete the formation of each of the base sections 11, 11' and 11". The covers 14, 14 and 14" may be formed in an identical manner except that the side walls 82-84 (the side walls all being indicated at 14a) of the cover are not cut to provide the openings 18.

The components of the carton may be assembled in much the same manner as already described. Initially the components including the base 11' and the cover 14 are formed to shape with the base 11 being provided with legs 12. Cushioning pads 19' are then inserted into the base and rolls 16 are supported upon the cushioning pads 19' and secured with the wall structure 13' by means of the roll holders 17'. The cover 14' is then secured with the base 11 in such a way that vertical side walls 514a are disposed in lapped engagement over the flanged end of the roll holders 17 to secure the roll holders 17 in unitary assembly with the wall structure 13'. Additional units identical to the one just described only without the legs 12 are assembled and stacked on top of the lower- 'most unit and the units are all secured in unitary assembly by mean of the straps In view of the foregoing description, it will now be seen how rolls may be securely attached in suspension with the side walls of a carton so that the rolls will not be damaged during shipment. The roll holders are of a reinforced structure capable of supporting heavy loads such as those imposed by rolls of the type described herein. These rolls when placed in a palletized canton, can be readily supported by a lift truck or the like to a truck or railroad car and conveniently shipped to the purchaser. Th carton itself can be economically manufactured and can be disposed of or reused as desired. Another advantage of a carton of this type is that its component parts can be shipped to a purchaser such as a roll manufacturer in knockdown form at a minimum of shipping expense. The components of the carton may be very suitably manufactured from a corrugated type of paperboard of any suitable type.

Although minor modifications might be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon, all such modifications as reasonably and properly come within the scope of my contribution to the art.

I claim as my invention:

1. In a method of packaging rolls of material, the steps of forming a palletized base with a vertical wall structure,

notching the wall structure to provide wall openings in opposing Walls,

disposing cradles about the wall openings for supporting the rolls, aligning tubular rolls between the opposing walls with the wall openings and supporting opposite ends of each roll by the cradles in close adjacency to the adjacent Wall openings to permit the rolls to be closely stacked without interference from the cradles, and

telescoping roll holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls from said opposing walls on the cradles.

2. In a method of packaging rolls of material, the steps of forming a palletized base with a vertical wall structure,

notching the wall structure to provide wall openings in opposing walls,

disposing cradles about the wall openings for support ing the rolls.

aligning tubular rolls between the opposing walls with the wall openings,

telescoping rolls holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls and supporting the rolls on the cradles, and mounting a cover on the side walls and engaging sides of the cover against a flanged end of the roll holders securing the flanged ends of the holders in locked assembly against the associated side wall of the wall structure.

3. In a method of packaging rolls of material, the steps of forming a base with a vertical :wall structure,

notching the wall structure to provide wall openings in opposing walls,

aligning tubular rolls between the opposing walls with the wall openings, forming roll holders each by punching a series of annularly disposed fingers from a sheet of material and turning the fingers laterally from the sheet and engaging rings against inner and outer faces of the fingers forming a tubular end on the roll holders, and

telescoping the thus formed tubular ends through the wall openings into the interior of the tubular rolls suspending the tubular rolls in spaced relation from said opposing Walls and engaging a flanged end of each of said holders against the outside face of the associated opposing wall.

4. In a method of forming a carton for rolls of packaging material, the steps of forming a palletized parallel sided cup-shaped base having legs projecting from its underside,

forming a parallel sided vertical wall structure from a length of paperboard,

cutting the wall structure to provide wall openings in opposing walls,

transversely folding the vertical Wall structure at spaced intervals along its length and attaching opposite ends together,

nesting the vertical wall structure in assembly in the cup defined by the cup-shaped base,

aligning tubular rolls between the opposing walls with the wall openings, and

telescoping roll holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls.

5. The method of claim 4 further characterized by attaching cradle pads to opposing walls of the vertical wall structure in alignment with the wall openings, and supporting the rolls on the cradle pads.

6. In a method of forming a carton for rolls, the steps of forming a base with a vertical wall structure,

cutting the wall structure to provide Wall openings in opposing walls,

punching out circular blanks from paperboard sheets providing the sheets with spaced circular holes, scoring the sheets with the score lines bisecting the circular holes,

folding the sheets along the score lines in such a way that the edges defining the openings are transformed into semi-circular notches for engagement with rolls to form cradle pads,

attaching the pads to the wall structure disposing the notches in alignment with the wall openings, aligning tubular rolls between the opposing walls with the wall openings,

forming roll holders each by punching a series of annularly disposed fingers from a sheet of material and turning the fingers laterally from the sheet and engaging rings against inner and outer faces of the fingers forming a tubular end on the roll holders, and telescoping the thus formed tubular ends through the wall openings into the interior of the tubular rolls suspending the tubular rolls in spaced relation from said opposing walls and from the cradle notches and engaging a flanged end of each of said holders against the outside face of the associated opposing wall.

7. The method of claim 6 further characterized by said scoring step including a partial slitting of each of the sheets leaving a folded section joining the folded sections together at one margin of each of the pads.

8. In a method of forming a carton for rolls, the steps of forming a base with a vertical wall structure,

cutting the wall structure to provide wall openings in opposing walls,

punching out circular blanks from paperboard sheets providing the sheets with spaced circular holes, scoring the sheets with the score lines bisecting the circular holes, folding the sheets along the score lines in such a way that the edges defining the openings are transformed into semi-circular notches for engagement with rolls,

securing the folded sheet in a folded state with the vertical wall structure with the opening aligned with the notches in side-by-side contiguous relation,

aligning tubular rolls between the opposing walls with the wall openings, and telescoping roll holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls and maintaining opposite ends of the rolls in engagement with the cradle notches. 9. In a method of forming a carton for rolls, the steps of scoring a parallel sided piece of paperboard at its margins and punching marginal wall portions forming openings in opposing wall portions, disposing cradles about the wall openings for supporting the rolls,

aligning tubular rolls between the opposing walls with the wall openings, and

telescoping roll holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls and supporting the rolls on the cradles.

10. The method of claim 9 further characterized by securing the roll holders with the Wall portions by forming and mounting a cup-shaped cover on the wall portions.

11. A method of packaging rolls which comprises forming a parallel sided wall structure by scoring a length of paperboard and attaching opposite ends and by cutting openings in opposed side walls, forming cradle support pads having notched ledges, attaching cradle support pads to the opposed side walls with the notched ledges in side-by-side adjacency with openings, lowering rolls into the interior of the wall structure and engaging opposite ends on the notched ledges defined by the cradle pads, and

inserting locking elements through the wall openings locking the rolls with the wall structure.

12. The method of claim 11 further characterized by forming a cup-shape parallel sided base from paperboard material, palletizing the base and mounting the wall structure in the cup defined by the cup-shaped base with the side walls of the cup being engaged with the locking elements to prevent accidental displacement.

13. In a method of forming a carton for rolls of packaging material, the steps of forming a palletized base with a vertical wall structure,

cutting the Wall structure to provide wall openings in opposing walls,

forming cradle pads with notched areas having diameters larger than the diameters of the wall openings and disposing the notches and the wall openings in side-by-side adjacency,

providing rolls having diameters approximately the diameters of the cradle notches and position the tubular rolls between the opposing walls with each .roll having its opposite ends supported in the notches of the cradle pads, and

telescoping roll holders from outside the opening walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls.

14. In a method of forming a carton for rolls of packaging material, the steps of forming a palletized base with a vertical wall structure, cutting the wall structure to provide wall openings in opposing walls,

forming cradle pads with notched areas having diameters larger than the diameters of the wall openings and disposing the notches and the wall openings in side-by-side adjacency,

positioning film rolls having roll diameters approximately the diameter of the cradle notches and with the film being spaced from opposite ends of each roll,

positioning the tubular rolls between the opposing walls with each roll having its opposite ends supported in the notches of the cradle pads with the fihn being free of the cradle pad notches to allow close stacking of the rolls, and

telescoping roll holders from outside the opposing walls through the wall openings into the interior of the tubular rolls securing and suspending the tubular rolls in spaced relation with said opposing walls.

References Cited by the Examiner UNITED STATES PATENTS 2,017,405 10/1935 Pantalone 20658 2,314,491 3/ 1943 Greenberg 206-46 2,494,730 1/ 1950 T-hursby 2296 2,607,476 8/1952 Rockefeller 20659 2,665,807 1/1954 Budd 20665 2,990,951 7/ 1961 F allert 20665 FOREIGN PATENTS 572,553 6/ 1958 Italy.

FRANK E. BAILEY, Primary Examiner.

S. ABEND, Assistant Examiner. 

1. IN A METHOD OF PACKAGING ROLLS OF MATERIAL, THE STEPS OF FORMING A PALLETIZED BASE WITH A VERTICAL WALL STRUCTURE, NOTCHING THE WALL STRUCTURE TO PROVIDE WALL OPENINGS IN OPPOSING WALLS, DISPOSING CRADLES ABOUT THE WALL OPENINGS FOR SUPPORTING THE ROLLS, ALIGNING TUBULAR ROLLS BETWEEN THE OPPOSING WALLS WITH THE WALLS OPENINGS AND SUPPORTING OPPOSITE ENDS OF EACH ROLL BY THE CRADLES IN CLOSE ADJACENCY TO THE ADJACENT WALL OPENINGS TO PERMIT THE ROLLS TO BE CLOSELY STACKED WITHOUT INTERFERENCE FROM THE CRADLES, AND TELESCOPING ROLL HOLDERS FROM OUTSIDE THE OPPOSING WALLS THROUGH THE WALL OPENINGS INTO THE INTERIOR OF THE TUBULAR ROLLS SECURING AND SUSPENDING THE TUBULAR ROLLS FROM SAID OPPOSING WALLS ON THE CRADLES. 